Instr. nr.: 851021 Vennligst referer til ved bestilling av reservedeler INSTRUKSJONER OG RESERVEDELS-LISTER FOR SMOREOLJE-KJOLER Type H 17 wc ULSTEIN Bergen Diesel as P.O.Box_ 924 Tel: (+ 475) 19 00 00 N-5002 Bergen Telefax:(+ 475) 19.0405 Norway Telex: 42 735 bmvh nA APV INSTRUCTIONS PLATE HEAT EXCHANGERS 1000 B-GB H17"° SERIAL NO. APVBAKERAS + 6000 KOLDING + DENMARK * PHONE+4575501133 © TELEX 51345 THERM OK * TELEFAX +4575503434INSTRUCTIONS CONTENTS 1) CONSTRUCTION - FUNCTION 4-1) PRINCIPLE OF THE PLATE HEAT EXCHANGER 1-2) EDGE-CLAMPED FRAMES 13) SPINDLE-CLAMPED FRAMES 44) FRAME TYPES +5) MOUNTING 16) _ EXAMPLE OF FRAME DESIGNATION 17) PLATE PACK - MEDIA 4.8) INTERMEDIATE FRAMES 19) SEPARATING PLATES 2) ASSEMBLY DRAWING - DIAGRAM 24) ASSEMBLY DRAWING 22) DIAGRAM 23) EXAMPLE 2.8) REFERENCE NUMBERS 25) PUNCH CODE 26) SERIAL NUMBERS 27) CAPACITY 3) PLATES 31) MARKING 32) GASKETS 4) MOUNTING INSTRUCTION 41) SPACE REQUIRED 42) DRAIN 43) PIPE CONNECTIONS 43) PRESSURE PULSATIONS/VIBRATIONS. 45) PERMISSIBLE PRESSURE 46) LIQUID HAMMERING 47) SHIELDING MACHINE PLATE 48) ASSEMBLING OF EDGE-CLAMPED FRAME 49) ASSEMBLING OF SPINDLE-CLAMPED FRAME 5) START-UP AND OPERATION 51) CLAMPING 52) START-UP 53) LEAKAGE DURING START-UP 5.4) VENTING 55) OPERATION 56) _ LEAKAGE DURING OPERATION PAGE im © wooooon yy = ° 11-15 " " n 2 2 13 13 13 14 15 16 16 16 16 16 16 166) 61) 62) 63) 64) 85) 86) 67 i) 7) 72) 73) 74) 75) 8) a4) 8-2) 8:3) 8-4) 9) 10) 11) 11.4) 11-2) 11:3) 12) 124) 122) 123) 124) SEPARATION AND ASSEMBLING COOLING AND PRESSURE RELIEF SEPARATION OF EDGE-CLAMPED FRAME SEPARATION OF SPINDLE-CLAMPED FRAME INSPECTION / CLEANING ASSEMBLING CLAMPING LONG WORKING BREAKS CLEANING MANUAL CLEANING CIP.CLEANING DETERGENTS CONTROL OF CLEANING CONTROL OF CLEANING FLUID CONCENTRATION REPLACEMENT OF GASKETS REMOVAL OF OLD GASKETS CLEANING GLUING NON-GLUE PRESTOFIX GASKETS REPLACEMENT OF PLATES RECONSTRUCTION FAULT-FINDING DECREASING CAPACITY LEAKAGE. VISIBLE LEAKAGE - NON-VISIBLE SPARE PARTS / ACCESSORIES PLATES. GASKETS STORAGE OF GASKETS. GUARDPLATES / INSULATING JACKET / CLAMPING TOOLS INSTRUCTIONS 16-18 16 "8 s " " * te 19-20 19 19 19 20 20 21 2 2 2 2 23 23 24 24 24 24 25-28 26 27 ar 28 ENCLOSURES AT THE BACK OF THE MANUAL Drawing No. LL 2S BPPG-% Diagram No.: LL PS 3723-0 Gasket table No. ALPS 00 808INSTRUCTIONS 1) CONSTRUCTION - FUNCTION 4-1) PRINCIPLE OF THE PLATE HEAT EXCHANGER The plate heat exchanger consists of a head built together with a carrying bar, a guide bar, and a column to a stationary frame. A follower is suspended between the column and the head. This movable follower slides along the carrying bar and is guided by the bottom guide bar. The plates are fitted with gaskets (fig. 1) and each plate is suspended between the fixed head and the movable follower. Compression of the plate pack within the plate heat exchanger frame is accomplished by either edge or spindle clamping. Each frame size can be designed with all connections on the fixed head, or some con- nections on the follower. Additional inlet and outlet connections can be provided by using an intermediate frame. All APV Baker plates are cold-pressed in var- ious materials chosen for each specific duty. The plates are pressed with special corru- gations which ensures turbulent flow between the plates and hence high heat transfer coeffi- cients. 1-2) EDGE-CLAMPED FRAMES Edge-clamped frames are clamped with bolts placed along the edge of the head and the follower, Depending on the size of the heat exchanger, this frame type is available both with and without column. 1-3) SPINDLE-CLAMPED FRAMES A spindle-clamped frame always includes a column. The frames are clamped by means of one of two spindles which extend from threaded bushes in the column and com- press the follower against the plate pack. For high pressure, this type of plate heat ex- changer can also be equipped with bolts placedalong the edgeof the head and follower. These bolts are not used for clamping, but for pressure absorption during operation. 1-4) FRAME TYPES The following designations are given to the various alternatives: E: One spindie - stainless - spindle-clamped T: Two spindles - stainless - spindle- clamped B: Bolts M: Painted, edge-clamped R: Stainless, edge-clampedFig.2 5) MOUNTING Ball type feet - adjustable Floor mounting Wall mounting Column 4 K G Vv s 1-6) EXAMPLE OF FRAME DESIGNATION MGS-16 M: Painted, edge-clamped G: Floor mounting S$: Column 16: Design pressure 16 kp/cm® (1.6 MPa) RK-10 R : Stainless, edge-clamped K : Ball type feet 10: Design pressure 10 kpicm? (1.0 MPa) INSTRUCTIONS me Fig.3 z Fig.5 1-7) PLATE PACK - MEDIA All plates are fitted with glued-on gaskets which, after clamping of the plate pack, en- sures an effective seal between fluids and at- mosphere (fig. 2). In addition, intermixing of the fluids is eliminated by a double gasket seal around the inlet ports (fig. 3). This en- sures that, in the unlikely event of a leakage, it is vented to atmosphere to give a visible warning. Every second plate in the plate pack is turned through 180°. This means that the double gasket seal occurs around every sec- ond inlet to the channels between the plates. The plate pack now forms a series of parallel flow channels in which the fluids flow in a counter current regime (fig. 4 and 5).INSTRUCTIONS 1-8) INTERMEDIATE FRAMES. In case of a plate heat exchanger operating simultaneously with e.g. up to six media in one and the same plate heat exchanger, in termediate frames are inserted (fig. 7) These intermediate frames divide the plate heat exchanger in various sections. The inter- mediate frames are equipped with exchange- able comer blocks (fig. 6). The corer blocks form the connecting link between the respective sections of the plate heat exchanger and/or connections for pipes. Two connecting branches can be provided in the same corner block with connection to their respective section in the plate heat ex. changer (fig. 6) 4-9) SEPARATING PLATES Plate heat exchangers with more than one section, but requiring no inlet/outlet bran- ches in'the separation can be equipped with separating plates (strong sheet, 210 mm), al- ternatively with flow plates equipped with re- inforced blankings. Fig.7INSTRUCTIONS 2) ASSEMBLY DRAWING - DIAGRAM 24) ASSEMBLY DRAWING (FIG. 8) FD = Head Inside the back pocket of this manual you M_= Intermediate frame will find an assembly drawing. This shows all BD = Follower principal dimensions as well as connection H_ = Horizontal connection specifications and identification. V_ = Vertical connection rate Fas Fig. 8 a (see also fig. 4 on page 5) Fig. 8 b 1 section 1 section 1 pass 2 passes "ymev eyo My ee “may : ann if gone mente” used a 2 5 = a), -—B2 s Riera] pte Tg eee F M 4 M] % rece atte! met | oS men F—5| 724) 4 2 | TolNwon owen Swan | ey wav | atv wow mew : wiv ‘woav ‘Moov Fig. 8c 5 sections *(M[1[2[H | [ '__ horizontally oriented f corner hole number — intermediate frame number from head (FD) — intermediate frame om 98 7INSTRUCTIONS mt BD FD Fig.9 Fig. 10 mH 5192INSTRUCTIONS 2.2) DIAGRAM (FIG. 10) Inside the back pocket of this manual you will also find a diagram showing the schema- tic plate configuration and fluid flow regime. The plate pack is suspended between the head (FD) and the follower (BO). The gasket side of the plates must always face towards the head (FD). On the right-hand side of fig. 10 can be seen a single plate viewed from the gasket sido. The corner holes of the plate are designated 4, 2, 3. and 4 as shown on the drawing Interconnecting lines have been drawn from the plate pack to the four corner holes of the plate. The flow channels tor each fluid are marked with a thick or a thin line to ease identification, 2-3) EXAMPLE Figs. 9, 10 and 11 show the same plate heat exchanger with a heating and cooling section separated by an intermediate frame M1 The cold fluid enters the heating section via F1 in FD and flows through two parallel chan- nels in one pass before entering the cooling section via hole 4 in the intermediate frame From here the fluid is cooled in two passes each with two parallel channels, before leav- ing the plate heat exchanger through B4 in the follower. The heating medium enters through head (F3 in FD) and leaves again through head (F2 in ). The cooling medium enters through follower (B3 in BD) and leaves through the comer block of the intermediate frame (M12H), 2.4) REFERENCE NUMBERS The material quality and reference number of the plates is stated in the top left-hand corer of the diagram fig. 10 (plate 1075 2356) - this number designates a plate without corner holes and without gasket. The letters V at the bottom and H at the top are explained in sec- tion 3) PLATES. 2:5 PUNCH CODE The four digit number shown over the plates {fig. 10) is a punch code and indicates which plate corner holes are open to allow fluid flow. For example: 1204* means that this plate is open in corners 1, 2, and 4, whereas corner 3 (0) is closed. 2.6) SERIAL NUMBERS The numbers of the diagram- under the plates - are serial numbers, Le. indication of the placing of the plates in the plate pack of the plate heat exchanger. Serial numbers start with number 1 for the head and after that continuous numbers for each plate, intermediate frame or separating plate. When extending the plate pack, the existing numbers are used, but the new plates are marked with an extra figure e.g. 16, 17, 18, 18 1, 18:2, 18:3, 18-4, 19, 20 eto. 27) CAPACITY The data list on the diagram gives the capaci- ties and other criteria used for the design of the plate heat exchanger. ton G8INSTRUCTIONS 3) PLATES 3-1) MARKING The plates are marked with material codes and reference numbers and also have the let- ter V or H stamped at either end (fig. 12). Looking towards the gasket side, the plate is designated a left plate when the V is upwards. or a right plate when the H is upwards. \V-plates have inlet and outlet via comer holes, 1 and 4, respectively. H-plates have inlet and outlet via corer holes 2 and 3, respectively (fig. 13) 32) GASKETS The gaskets are cemented into a groove along the edge of the plate. The gaskets for V and H-plates are identical. This means that V and H-plates with gaskets are identical, but by turning through 180° seal off alternating corner holes in every second plate (fig. 13). Serial number Code of materials {always to be specified when ordering single plates) ay Fig. 12 Four last digits of plate reference number or 10INSTRUCTIONS 4) MOUNTING INSTRUCTION 4-1) SPACE REQUIRED The plate heat exchanger should be placed in such a way that service and inspection can easily be effected It must be possible to take off guardplates or insulating jacket, if any, without having ne- cessarily to remove the connecting pipes. This must be considered when installing the unit. All engagements are carried in a straight pipe section without thermometer, manometer or draw-off taps at a distance of 100 mm from the unit (more in case of in- creased insulating thickness). The distance to finish-insulated pipes should be 100 mm ‘rom the insulating jacket guardplate. The follower must be free to move along the full length of the carrying bar as shown in fig. 14. Onat least one side of the plate heat exchan: ger there must be sufficient space to unhook the plates from the carrying bar by a slight tilt away from the vertical (fig. 15). At the same time it must be possible to tight- en or remove the clamping bolts and inspect the plate heat exchanger. 42 DRAIN Ideally a drain should be located close to the plate heat exchanger. If the drain leads to public sewage system, the possible risk of pollution should be considered. If either fluid cannot run directly to drain, suitable spill trays should be placed beneath the unit. If necessary, these should be fitted with a level alarm. 4-3) PIPE CONNECTIONS The plate heat exchanger must be connected up according to the enclosed assembly draw- ing. All pipe connections must be carried out in such a way that the plate heat exchan- ger can easily be opened for inspection. Threaded connections should be mounted ei. ther with unions with plane tightening or unions with conical tightening connected to bends. Flanged connections must be removable. Fig. 164 shows a correctly connected unit whilst 16B shows an arrangement that must not be used under any circumstances! If necessary, a suitable filter should be in stalled on the fluid inlet. Isolating valves are also recommended on all connections. Thermometers, pressure gauges etc. should be used as required for moni- toring the plate heat exchanger performance. Fig. 14 Fig. 15 wom BoB 1INSTRUCTIONS CORRECT PIPE MOUNTING FIG. 164 In order to permit possible replacement of rubber liners in connections, the pipe joints on the head (FD) 1 and 2 and the follower (BD) 3 and 4 must be connected to removable pipe sections. In addition, the pipe joints on the follower (BD) 3 and 4 must be removable in order to enable the plate heat exchanger to be opened for cleaning and inspection. During opening, it must be possible to move the follower (BD) 5, without hindrance, along the full length of the carrying bar. For re-tightening of the plate pack, the pipes onto the follower (BD) 5 and any intermediate frames must be flexible. This can be achieved by the use of expansion joints. To prevent undue strain on the plate heat exchanger from the connecting pipes, all pipes must be unloaded by suitable pipe holders. For CIP (cleaning in place), without opening, piping material and layout must be chosen accordingly. ® 4-4) PRESSURE PULSATIONS / VIBRATIONS Piston pumps, gear pumps, dosing devices etc. must not be able to transfer pressure pulsationsivibrations to the plate heat ex- changer as this may cause fatigue fracture in the plates. 4.5) PERMISSIBLE PRESSURE Working, testing and maximum differential pressures for the plate heat exchanger are given on the metal machine plate on the head (fig. 17). WORKING PRESSURE = the highest pressure to which the plate heat exchanger may be subjected during operation! TESTING PRESSURE = the highest pressure at which the plate heat exchanger may be tested! DIFFERENTIAL PRESSURE = the maximum permissible difference in pressure from one side of the plate to the other. For plate heat exchangers with several seo- tions, the stated working and testing pres- sures only apply ifall sections are pressurised If each section operates at different pres- sures, or one of the sections is not under pres- sure, leaks may occur in the lower pressure section. Fig. 16B se?INSTRUCTIONS The maximum permissible difference in pres- sure between two sections separated by an intermediate frame (M) is 6 kp/cm? (0.6 MPa). If the two sections are not equal in size, the permissible difference in pressure is reduced. EXCESS PRESSURE PROTECTOR must al- ways be mounted (fig. 18), if the plant is likely to develop a higher pressure than that stated ‘on the machine plate. This condition may a: rise during pump start-up, expansion or valve change-over etc 4.6) LIQUID HAMMERING The plate heat exchanger is sensitive to liguid hammering. This can occur during regulation, change-over, pump start-up etc. In order to avoid this situation, the use of throttling of air-operated valves, damping relays in electri- cal control gear, automatic pump start with closed valves ete. is recommended. 4-7) SHIELDING The plate pack must be shielded, when: * possible splashes may cause damage * corrosive media are being used * the working temperature may cause scalding * required by the local authorities APV Baker can supply guardplates for all plate heat exchanger types. When thermal shielding is desirable or required, an insulating jacket can be supplied. This jacket fits the heat exchanger exactly and can be taken off without removing the connecting pipes. APV BAKER AS {6000 Kolding Denmark Tel: + 45 5 50 11.33, ‘Telex: 51 345 Therm DK TYPE/YEAR [eee | [oo ‘SERIAL NO. (aes DRAWING NO. —— nomcapactty §=[__ Ld HEAT TRANSFER SURFACE m? [_] WORKING PRESSURE = 7 TEST PRESSURE ear] VOLUME PROD /MEDIUM Litre WORKING TEMP:MAX/MIN. °C TTT IMPORTANT: MAX/MIN MM “The instructions inthe cz instruction manual ae to be strictly observed during instalation and operation e Fig. 17 ‘wo 868 134-8) ASSEMBLING OF EDGE-CLAMPED FRAME (FIG. 19) * Start by erecting the head (FD). Secure the guide bar (E) to the head by bolts and block it up (1), bolt the column (2) on the guide bar (E) * Place the follower (BD) on two blocks (3) approx. 200 mm from the head (FD). Place two spacer blocks (4) at the top between the head and the follower. Retain the follower (BD) with a rope (R), and remove the scotching (1). * Bolt the carrying bar (C) on the column and the head with the fittings (6). * Fit the fittings with rollers (6) on the follow- er (BD), so that the rollers are exactly op- posite each other. Mount the guide fitting (7) on the follower. Adjust the height of the follower by means of the roller fittings. Re- move the blocks (3 and 4) and the rope (R) * Push the follower to the column. Worm the plates (A) on the carrying bar one by one, turn them over the guide bar, and push them towards the head. Insert the plates in serialnumerical order as stated in the di- agram. The serial numbers must be up- wards and the gasket side must face to- wards the head. * When all the plates have been correctly as- sembled, push the follower against the plate pack - mount the clamping bolts (H) - apply a high-pressure lubricant to the threaded ends of the bolts. Clamping should be carried out using a ratchet span ner (6) or a similar suitable tool. Start clamping with two bolts diagonally ‘opposite each other. These bolts can be tightened almost_to the minimum plate pack dimension. Continue by clamping all bolts in a diagonal manner. ‘On completion, the head and the follower must be completely parallel! The minimum clamped plate pack dimen- sion is shown on the machine plate on the head (fig. 17, page 13). Fig. 19 INSTRUCTIONS 14INSTRUCTIONS 4.9) ASSEMBLING OF SPINDLE-CLAMPED FRAME (FIG. 20) * Apply ahigh-pressurelubricant tothe thread of the carrying and guide bar. Erect the head (FD), fit in the guide bar (E) with the guide pin’ turning towards the head and clamp it. Block up the guide bar to horizon- tal position (1). * Lay a board (3) on the guide bar - place the follower on top of this, swing it up towards the head, and attach it to this with a rope (R). * Fit the carrying bar (C) with the guide pin turning towards the head and attach it Place a strong board (4) between the guide and carrying bar. The two bars must be pa- rallel. Adjust the column (2) to correct height by means of the adjustable ball type feet and attach it on both guide and carrying bar. Mount the supporting fittings for the follow- er on the carrying bar. Remove the scotch- ing (1), boards (3 and 4), and rope (R). * Tighten up the nuts (6), and level the frame by means of the adjustable ball type feet, which must be unloaded during adjust- ment. Apply ahigh-pressure lubricant tothe thread and axle journal (6) of the spindle. Screw the spindle into the threaded bush ing of the column. Apply a high-pressure lubricant also to the thrust pad (7) and the sliding surface of the carrying bar. * Push the follower to the column. Worm the plates (A) on the carrying bar one by one, turn them over the guide bar, and push them towards the head. Insert plates/intermediate frames in serial numerical order as stated in the diagram Serial numbers must turn upwards, and the gasket side must face towards the head * Push the follower against the plate pack, and insert the push rod (8). Adjust the height of the follower by means of the ec- centric axle journals on the supporting rol lers, so that the spindle centres with the thrust pad on the follower. Use a ratchet spanner (9) (or a similar suitable tool) for clamping. The clamping measure is indica- ted on the machine plate (fig. 17, page 13). Fig. 20 1090 B68 15INSTRUCTIONS 5) START-UP AND OPERATION 541) CLAMPING Before the initial startup, check that the clamped plate pack dimension is as specified on the machine plate (fig. 17, page 13) on the plate heat exchanger in question 5:2) START-UP Sudden pressure surges must be avoided as these may cause leakage or damage to the plates and gaskets. Pumps should therefore be started against closed valves which can then be gradually opened until the desired flow rate is achieved. Ina plate heat exchanger using steam as the heating media, the cold fluid should be intro- duced to the plate heat exchanger before the steam is turned on. The above precautions apply to all types of plate heat exchangers during start-up. The potential damage possible due to in- correct start-up increases proportionally with increased liquid flows and the length of connecting pipework! Plate heat exchangers with new EPDM gas- kets should be started up (initial start-up) by increasing the temperature slowly, max. 25°C (77°F) per hour. 5.3) LEAKAGE DURING START-UP During the initial start-up, minor leaks may occur until the plates and gaskets have reached their design working temperature and all sections are correctly pressurised. 5-4) VENTING When correct working temperature and work- ing pressure have been reached, the system must be vented. The air in the plate heat exchanger is driven out by the liquid flow, provided that the capa- city is as stated in the diagram Air in a plate heat exchanger reduces the heat transmission and increases the pressure drop, thus increasing the risk of corrosion! 5.5) OPERATION During operation, temperatures and pressure drops must be regularly checked, Increased pressure drop and/or falling temperatures indicate that there are coatings on the plates. The plate heat exchanger now needs clean- ing. During operation, the same precautions a- gainst rises of pressure must be observed as during start-up! 5-6) LEAKAGE DURING OPERATION See section 11 »FAULT-FINDING«. 6) SEPARATION AND ASSEMBLING 6-1) COOLING AND PRESSURE RELIEF Before opening the plate heat exchanger, it must be cooled below 40°C (104°F), and it must not be pressurised! 6-2) SEPARATION OF EDGE-CLAMPED FRAME Keep two diagonally placed bolts clamped - dismount the rest of the bolts - take care that the follower (BD) does not keel over! Loosen the two last bolts uniformly (max. dif- ference 25 mm) - then push the follower to- wards the column (fig. 21). NOTE! When using plate heat exchangers on board ships, the follower (BD) must be se- cured in order to avoid danger during the movements of the ship at sea 6-3) SEPARATION OF SPINDLE-CLAMPED FRAME Remove securing bolts, if any - then loosen the spindle. When using frame types with two spindles, loosen the two spindles uni formly (max. difference 25 mm) - then push the follower (BD) towards the column (fig. 22). 16INSTRUCTIONS fe Ci i iN / | | s 2 6-4) INSPECTION / CLEANING Check every plate gasket carefully! Before assembling, both plates and gaskets must be completely clean! Remove settlings, scalings, cakings, if any, from the plates, Where lubricating oils have been used, de- grease the gaskets and the joint faces of the Plates! Even tiny impurities such as grains of sand or bristles will cause leakage and may damage the gaskets. 6-5) ASSEMBLING If the plates have been dismounted, they must be correctly inserted according to serial numbers! The head has No. 1, and the serial numbers of the following plates and the intermediate frames, if any, are No. 2, 3, 4, 5 etc. The serial number is marked in the top right- hand corner of the plates - do not forget that re side must face towards the head (FD). wm ca Ae:INSTRUCTIONS Fig. 23 6-6) CLAMPING The minimum dimension for clamping is stated onthe machine plate (fig. 17, page 13) placed on the head - and the assembly drawing The plate heat exchanger must be clamped to minimum measure + 0.05 mm per plate. APV Baker recommends clamping to minimum measure after approx. one month's operation - alternatively, immediately after installing new plates or new gaskets. New gaskets in EPDM quality are clamped step-wise the first time: 1. Minimum measure + 15% 2 hours’ interval or more. 2, Minimum measure + 7.5% 12 hours’ interval, preferably more. 3. Minimum measure + 0.05 mm per plate, alternatively minimum measure. The head and the follower must be exactly parallel, Therefore, clamping must be mea- sured at the top and the bottom and on both sides of the head and the follower! (fig, 23) MEASURED WITHIN THE EDGE (oniy for spindle-clamped frames) 67) LONG WORKING BREAKS If the plate heat exchanger is out of operation for a long time, it is advisable to empty it, separate the plates, and clean the unit. Clamp the plate heat exchanger lightly to- gether, and leave it covered in order to protect the gaskets against dirt and the effect of light! 187) CLEANING The capacities and resistance to corrosion of plate heat exchangers depend on the plate pack being kept clean. Coatings on the plates can be removed man- ually or through CIP-cleaning - cleaning in place. 74) MANUAL CLEANING After separation of the plate heat exchanger, remove the individual plates and clean them with a soft brush and a suitable detergent (see 7-3). In case of thick layers of scale or or- ganic materials, the plates can be placed in a vessel with suitable cleaning fluid. Do not in any circumstances use steel brush, metal scraper or similar scraper tools which will damage both plates and gaskets. A high- pressure cleaner can be used with care - however, never with sand or similar abrasives added. 7-2) CIP-CLEANING A condition for using CIP-cleaning (cleaning in place) is that the coating of the plates is soluble, and that all materials in the system of circulation are resistant to the cleaning fluid used. Cleaning can also be effected without circu- lation by pouring a suitable detergent into the system (7-3). INSTRUCTIONS After some time of standing, wash out the detergent again with clean water. Cleaning by circulation requires the estab- lishment of the necessary circulation system. For the correct quantities of circulating deter- gents, see the enclosed diagram. EXAMPLE OF CIP-CLEANING PROGRAMME * Drain-off product residues and cooling / heating media + Rinse with cold or lukewarm water * Circulate with warm cleaning fluid solution * Rinse with warm water * Rinse with warm water with softener ad: ded to it * Rinse with cold or lukewarm water 7-3) DETERGENTS The definition of a suitable detergent is brief and to the point. Coatings on the plates must be removed without damaging plates and gas- kets. It is important not to decompose the passivating (protective) film of stainless steel - the film contributes to preserving the re- sistance of the steel to corrosion. Do not use chlorine-containing agents such as hydrochloric acid (HD1)!!! 19INSTRUCTIONS EXAMPLES * OIL AND FATS are removed with a water emulsifying oil solvent, e.g. BP-SYSTEM CLEANER. * ORGANIC AND GREASY COATINGS are removed with SODIUM HYDROXIDE (NaOH) - max. concentration 1.5% - max. temperature 85°C (185°F). 1.5% concen- tration corresponds to 3.75 1 30% NaOH per 100 | water. * FURRINGS AND SCALE DEPOSITS are removed with NITRIC ACID (HNO) max. concentration 1.5% - max. temperature 65°C (149°F). 1.5% concentration corresponds to 1.75 1 62% HNO per 100 | water. Nitric acid has an important constructive effect on the passivating film of stainless steel. 7-4) CONTROL OF CLEANING The plate heat exchanger must be opened for inspection at regular intervals. This is especial: ly necessary during the running-in period, until experience has been gained on the ef- fectiveness of the cleaning process. Through these inspections, it will gradually be possible to determine circulation times, temperatures and chemical concentrations with great certainty! Insufficient cleaning is most often due to: * Too small circulation quantity * Too short cleaning period * Too low chemical consumption in rela tion to the coating of the plates * Too long periods of operation 7-5) CONTROL OF CLEANING FLUID CONCENTRATION SODIUM HYDROXIDE (NaOH) solution is ti- trated with 0.1 n HYDROCHLORIC ACID (HC1) with methyl orange or methyl red as indicator. NITRIC ACID (HNO,) solution is titrated with 0.1 n SODIUM HYDROXIDE (NaOH) with phe- nolphthalein as indicator. The concentration of the cleaning fluid in % can be calculated from the titration result ac- cording to the following formula: _bxnxmy CONCENTRATION =PX220Ty% a= ml cleaning fluid taken out for titration b= ml titration liquid used for change of colour n= normality of titration liquid m= molecular weight of cleaning fluid (NaOH molecular weight 40 - HNO: molecular weight 63). 20INSTRUCTIONS 8) REPLACEMENT OF GASKETS On the diagram inside the back pocket of this manual you will find an order list for gaskets and details of glue type and quantity. Also given is information concerning the degreas- ing solvent for the new gaskets. The first plate after the head og intermediate frame is called an end plate and must have a gasket in all grooves. These gaskets are, in fact, two »normal« gaskets cut in half an glued in place around all grooves. You should carefully note how the old gaskets are as- sembled before removing them! 8-1) REMOVAL OF OLD GASKETS * PLIOBOND glued gaskets can be loos- ened by heating in water at 100°C (212°F). The plates are cleaned, and coatings, if any, are removed. See section 7-3 on page 19. 8-2) CLEANING New gaskets and the gasket grooves of the plates are cleaned with a cloth moistened with degreasing agent. The gluing surfaces must be absolutely clean - without finger prints etc. As degreasing agent use what is stated on the enclosed diagram. Alternatively, use: TRICHLOROETHYLENE, CHLOROTHENE VG, ACETONE, METHYL ETHYL KETONE or ETHYL ACETATE. It is important that all the degreasing agent has evaporated, before the glue is applied. This will normally take approx. 15 min. at 20°C (68°F). Itis advisable to clean the gluing surfaces of the gaskets with fine-grain sandpaper instead of degreasing agent. 8:3) GLUING » PLIOBOND 25, which is a nitrile rubber jlue on solvent basis (25% solids), is applied with a brush in a thin layer on the backs of the gaskets. The gaskets are put to dry in a clean and dustless place! The gasket grooves of the plates are now coated with a thin layer of glue, and the gaskets are cemented into the grooves. The insertion of gaskets start at both ends of the plate - and continues with the straight sections along the edges. The gluing process is most easily effected by laying the gaskets and the plates on a table - as the gaskets are cemented into the grooves of the plates, the plates should be stacked. The plates with the gaskets are now suspend- ed in the frame which is clamped lightly, for rubber gaskets e.g. to the minimum dimen: sion indicated on the machine plate plus 0.2 mm per plate. The plate heat exchanger is heated to 90- 100°C (194-212°F) by means of water or steam - the temperature must be kept for 11 to 2 hours! The liquid pressure must be kept as low as possible. On plate heat exchangers for food, pipe branches which are not connected to water/steam must be kept free, in order to permit glue vapours to escape! If there is no possibility of heating the plate heat exchan ger, it must stand at a place as warm as pos- sible with dismounted connections. The dry ing time will at 20°C (68°F) be approx. 48 hours. At e.g. 40°C (104°F), the drying time is reduced to approx. 24 hours When the glue vapours have vaporized, the plate heat exchanger can be clamped again as stated in section 66 on page 18. 218-4) NON-GLUE PRESTOFIX GASKETS PRESTOFIX is a non-glue gasket designed as aconventional gasket. Itis designed with a spe- cial clip-on feature which locks it into recesses in the gasket groove on the plate. (Fig. A). When replacing PRESTOFIX gaskets the old gasket is removed completely. Before fitting the new PRESTOFIX gasket check that the plate gasket groove is clean and free from residual rubber, particularly in the clip-on pockets, New gaskets are mounted by means of a small tool. The new gasket is placed in the gasket groove and the clip-on features are pushed with the mounting tool sidewise into the outer pockets of the groove. Then the clip-on fea- tures are pressed into the pockets on the inner side. (Fig. B) INSTRUCTIONS The PRESTOFIX gasket is centred in the gas- ket groove and locked securely by the recess. on both sides of the gasket groove. Thus the PRESTOFIX gasket will always be able to resist the tension which will inevitably arise when the plate heat exchanger is disassembled. (Fig. C) The first plate after the head and the intermedi- ate plates which have no physical contact with the product are equipped with a glued gasket as described, see 8.3. However it wll seldom be necessary to change these as their only pur- pose is to fill out the gasket groove thereby supporting the rest of the plate pack. ‘The PRESTOFIX gasket is available for food as well as non-food purposes. When assembling, the EPDM quality gasket should be wiped with a cloth wetted with silicone oil to facilitate the separation from the connecting plate when dis- assembling the plate pack. 22INSTRUCTIONS 9) REPLACEMENT OF PLATES Before inserting a spare plate in the plate pack, it must be checked that the spare plate is identical with the defective plate - the same corner holes open, and the marks V and H must face right. A defective 4-hole plate can be removed from the plate pack without inserting a spare plate, if the adjoining 4-hole plate is also re- moved. The new number of plates will then be=S2, This changes the clamping measure of the plate pack to M1 which will be: _MG2) Mia& M = The original clamping dimension stated on the machine plate, S = The original number of plates in the plate pack. The transmission area of the plate heat ex- changer is reduced in relation to the original number of plates. At the same time, the pres- sure drop will increase. 10) RECONSTRUCTION The modular construction of the plate heat exchanger ensures an easy extension or pos- sible reduction in the capacity. (Fig. 24) ay HI ui Fig. 24 ‘APV Baker's files contain the data of all sup- plied plate heat exchangers. All the customer has to do is to state the type designation, serial number and the wanted change - and APV Baker will submit a suggestion/quotation for the reconstruction. m0 BB 2311) FAULT-FINDING 11-1) DECREASING CAPACITY In case of reduced heat transmission and/or increasing pressure drop, the plate heat exchanger must be opened and the plates cleaned - after that, the exchanger is clamped again to the dimension stated on the machine plate. 11-2) LEAKAGE - VISIBLE * Check if the plate heat exchanger is opera- ting with higher pressure than the permissi- ble working pressure. If so, the pressure must immediately be re- duced to the correct working pressure. * Tighten up the plate heat exchanger - how- ever, never under the stated minimum dimen- sion! Never tighten up, when the plate heat ex- changer is under pressure! Check that the head and the follower are parailel after tightening-up! * Separate the plate heat exchanger for in- spection. Check if the plates are deformed or fouled. Check that the gaskets are elastic, non-deformed, and that the faces of the joints are clean. Clean very carefully all plates and gaskets before assembling the plate pack - tiny impurities such as sand grains may cause leakage! * If the plate pack is still leaky after cleaning and tightening to minimum dimension, it is recommended that you change the gaskets. * Leakage through the drain holes of the gaskets may occur. The reason is either that the gasket to the drained area is defective - or that the plate is badly corroded in the drain area! INSTRUCTIONS 11-3) LEAKAGE - NON-VISIBLE The leakage is ascertained by the fluids get- ting mixed and is due to holes in one or several plates - it can only be repaired by replacement of the platels in question. A suspected leakage can be localized in the following ways: * Remove the pipe on one of the lower pipe connections - then put the opposite side un- der pressure. If the medium continues to run out of the lower pipe connections - after the pressure has stabilized - several plates are leaking! Dismount the plate pack and check each plate carefully. Check suspected plates with a dye pene- trant! * Separate the plate heat exchanger, and put all plates to dry. Suspend the plates in the plate heat exchan- ger again and re-clamp. Circulate medium at full capacity on one plate side (every second plate channel). Keep the other plate channels un-pressurised and free from liquid! Stop the circulation after some minutes of operation and open the plate heat exchanger again. Take care to avoid water spraying onto the dry plate side! By a careful study of the plates it will be pos- sible to find moist areas, if any, on the other- wise dry plate sides, Check these areas with dye penetrant! * Separate the plate heat exchanger and check alll plates with dye penetrant! 24INSTRUCTIONS 12) SPARE PARTS / ACCESSORIES Generally, we distinguish between two frame types - an edge-clamped frame (fig. 25) and a spindle-clamped one (fig. 26). When ordering spare parts, please use the following disignations according to figures 25 and 26: uardplate (page 28) lead-in socket (page 28) insulating jacket (page 28) Noasenstzmo When placing any order, please state the type and serial number of the plate heat exchanger, which can be taken from the ma- chine plate! YEAR TYPE SERIAL NO. DRAWING NO. ORDER EXAMPLE: 8 clamping bolts with nuts - total length 725 mm - plate heat exchanger type M 92- serial number 19651. FDA BD C FD A C BD 2 wo 869, 25INSTRUCTIONS 124) PLATES One or several plates in a plate pack may be damaged - this will necessitate a replace- ment of the plate/s in question. In case of corrosion, all plates in the section in question as well as the whole plate heat exchanger must be examined very carefully! Fatigue fracture normally necessitates a re- placement of all the plates - there is a risk that the whole material is close to the fatigue-fracture limit The physical conditions around the plate heat exchanger must be carefully checked in order to localize the causes of the damage! When ordering plates, please state the serial numbers of the plates and the type and serial number of the plate heat exchanger. The serial numbers of the plates can be found in the top right-hand corner of the plates (fig. 12, page 10) - the type and serial number of the plate heat exchanger can be taken from the machine plate! ORDER EXAMPLE: 4 plates with glued-on gaskets, serial num- bers 11, 12, 13, and 14 - plate heat exchanger type H 17 - serial number 19 156 ORDER EXAMPLE OF A COMPLETE SET OF PLATES: 1 complete set of plates with glued-on gas- kets - plate heat exchanger type M 107 - serial number 28 452. ORDER EXAMPLE OF A COMPLETE SET OF PLATES FOR ONE SECTION: 1 complete set of plates with glued-on gas- kets for the heat recovery section - plate heat exchanger type K 55 - serial number 32 254, The plates are marked with a material code (fig. 42, page 10) symbolizing the steel quality. The four digits after the letter are APV Baker's inter- nal press operation number. When knowing the material code, APV Baker can procure a certificate of the plate. MATERIAL CODE: CODE DESIGNATION PREVIOUSLY |USED CODE A xs N < Stainless steel W 1.4301 (Als! 304) Stainless steel W 1.4436 (AISI 316) Stainless steel! W 1.4449 (Avesta 832 SL) Titanium ASTM B 265 grade 1 Stainless steel! W 1.4401 Stainless steel W 1.4539} (Avesta 254 SLX) Stainless steel (Avesta 254 SMO) HASTELLOY C276 Monel Cul ICEGJMR DFHKNP ze 26INSTRUCTIONS 12:2) GASKETS A complete set of gaskets comprises both gaskets for plates as well as lead-in and rub- ber sockets for lead-in bushes where appli- cable. ORDER EXAMPLE: 1 complete set of gaskets and glue for plate heat exchanger type H 12 - serial number 37 999, When ordering a few/several gaskets, please state the serial numbers of the plate/s and the type and serial number of the plate heat exchanger. ORDER EXAMPLE: Gaskets and glue for plates with serial num- bers 17 and 18 - plate heat exchanger type P 105 - serial number 29 899. The rubber quality of the gaskets is identified through colour marking NITRILE: No colour marking BUTYL YELLOW colour marking EPDM: GREY colour marking VITON: VIOLET colour marking Colour marking -_ 12:3) STORAGE OF GASKETS Gaskets must - irrespective of material - be treated with care! Rubber gaskets must not be bent sharply trodden on - and on the whole not be subjec- ted to deformation! The best means of storage of rubber gaskets is spread on shelves and stacked in small piles in a dark room or covered with black Plastic! ‘They can lie folded, but must have a radius of min. 100 mm and still only in small piles! Rubber gaskets MUST ALWAYS be stored on their side! The storage temperature lies between ap: prox. 25°C (77°F) and — 10°C (14°F) * Rubber gaskets must never be exposed to direct sunlight or ultra-violet rays! * Rubber gaskets must not be exposed to welding light, sparks etc.! * Rubber gaskets must always be kept apart from various liquids and their vapours! oto B48 27INSTRUCTIONS 12-4) 1 GUARDPLATES 12-4) 3. CLAMPING TOOLS 124) 92 Nut tightener hydraulic 124 33 Nut tightener electronydrauilic 28Betegnelse Description Bezeichnung Luor poe breshwakenin} ete eee: nlet __| Freshwater outlet _ 5000 Kolding Danmark | | erwin SYSAV -SS-06 #170 175 3779-2Pakning/Gasket/0schtur PARACLIP" pakning/-gasket/-Dichtung Heteriele/Material ade No Nateriale/Material Code No. im 008 Na 1075 1411 Pom 1075 1039 POM 107s 1438 Pred 1075 1152, rou [Pre ee TOFIX" pokning/-gasket/-Dichtung a8. Nateriale/Material Code No. wa ero __| 107s 39 GB D I ner afdeting skal den tn each section, the first In jeder Abteilung wird die ferste plade efter fast plate after the'head (FD) or erste Platte nach dem festen eksel (FO) eller nel en- the connector plate (F) is. DecKel (FO) oder der Anschluss rama (3) forsynes to be equipped with 2 gasket Platte (X) nit einer Oicntung pakning, sileces at der, so that there is a gas versohen, damit alle Dicntungs har pladen er montere ach gasket. groove when Spuren sit Dichtungen versenen Stativet, er pakninger | plate nas been nountes in the Sind, wenn die Platte in Gestell aie pakrungsspor Frame. nontiert worden 1st, 2 pawninger tilskéres son 2 gaskets are cut up as shown, 2 Dichtungen werden zugeschnit~ Wist 09 Micrneringene "2 and the corner rings "a" ere’ ten, und die Eck-Ringe "a" wer= afskares veo njoner, hor GUL away at the corners where dan’an den Ecken adgeschnitcen, der ar monteret en pakning a gasket has Deen mounted In wo eine. Dichtung im eckel oder wdnktel eller mellenrange. ihe ead or the connactar in der anschlussplatte aontiert plate worden 15 Pakning for nisrneklods Gunaimuffe for gennentoring By gennenoring Materiale ghar uiners Fur agzale Sagket for corner block Material Sarasin and nozzle Suigiinorre tar Oupanreruns Dichtung fur Eekklotz une Durenfanrung FD 8D FD" BD" Ta oat 1615 tae 0508 1085 1173 7085 1025 oa Tose 1623 was 0570 7085 1181 1085 114 Toes 1203 1035 1187 FEM pT-2 ‘For njornekiodser p§ nellenrammer skal nej pakning placeres pd den side af pladen,der svarer til (Fb) Fast deksel, og lav pakning p§ den side der svarer til (80) Devageligt deksel For corner plocks on connector plates the figh gasket is to be placed on the side which corre- sponds to tne head (FO), ond the thinner gasket on tle side which corresponds to the follover 80). Fur Eckklétze auf Anschiussplatten ist die nohe Dichtung auf der Seite der Pl die dem Festen Deckel (FD) entspricnt, und die niedrige Dic oie dem Beweglichen Deckel (80) entsprich tte anzubringen, ung aut der Seite anzubringen, NOR Pom rem Farvenarkning af pakningskval tet: agen gra violet Colour marking af gasket quality none Grey violet Farbenkennzelchnung der Oichtungsqualitat, ketne Brau vialett PAKNINGER APV Baker GASKETS DICHTUNGEN H17-15 Sign. 64.11.23 om Ant @€O127 AE. Sider al 2“PARACLIP™ Joint/-~Junta/ tipoxnanxa D Tatierenaterieiy Gols wos Matiére/s * ti brefwter ae Wo, qeeggrereriny/ Tove x 188 in Tors Tan 1087 ep 1075 108 [eon ue [075 188 EPDM Brum 1075 1039 “PRESTOFIX" Joint/-Junta/,Sipecroex” im 7 aa Tatibre/mterta? | Gove Wo v bm £122 Meropnar ona Pr Teh in ero te ws ee ng ei Oo ee ee po ge Ma Melts thet Sow Gal's edticor sopnenbr (Acer Yoana! mg a ete gcter tats te bath fms eaten Seb poem wr ne Sea aah Woe untastta'el cdeast Tirw'eien 20h Sapa, ean tsar “, Matiare Manchon en caoutchouc pour traversée Joint pour pi&ce angularie 22 te erseh naterial asquiito ce goms pare conextén, Junta pare taco esquina y coneten haseraan a poxnamn 208 yrnoR0r0 6neKe FO BD FD" BD" wwe [| __ 1004 1015 To84 0503 Toss 1173) 1085 vo2s oN Be Tose 1628 184 0570 Toes ver 108s tie marae Toes 1203 | 1085 1157 Hour blocs angulaires a cadres intermédiaires, Je joint haut doit @tre placé sur Le coté de plaque correspondant au bali (FO), et le joint bas sur le coté correspondant au plateau de serrage. Para bloques de esquina en bastidores separadores se colocan 1a empaguetadura gruesa en al lado de la placa, que corresponde al cabezal firme (FO), y la empaquetadura delgada en el 1ago de le place, que correspande al cabazel movil (BD). Tipw yraowx 6xoKax Ha npowexyTOWNX HarTEX wLOKAN NpoNLaAKA soAKHA Gury pasegeHA Mp TOR cTOPOMe naacmiMl, Koopa eae Neosat nar (F2) n mnan mpowaaaya Apa tare pastnea ht TOR crop, xITOPIN cramer Fam Marquage de coteur ne Eron_ de la qualité de joint aucun Ts Macaci6n en color tan “evo em de las cualidades de te junta: “ningGn aris VioTade 1 ns om Kpacka npoxnanea onevtaTne Eeoan xpacka enoneeomsn APV Baker PAKNINGER St GASKETS H17-15 DICHTUNGEN Side 2 ala ‘Sign. 64.11.23 Bh [Ant G@O1E7_sd=_[Rev. 90.01.05 Juul831218 BERGEN DIESEL instruction No.: © 831218 When ordering spare parts, please refer to this No. MODELS A & B THERMOSTATIC VALVES AMOT Thermostats offer the following advantages for automate engine jacket water and lubricating oll temperature control: © Large capacity combined with light weight. © Excellent reliability even under extreme shocks and vibration. © No external bulbs or tubing to break and cause trouble. © Operating forces are very large and with no packing glands, there It no chance of valve ever sticking or becoming inop- erative. ‘© Holds close regulation and is not sensitive to pressure. © Temperature is fixed and cannot be tompered with. © Because of its simple and rugged construction, practically no maintenance is ever required. © Compact in size, and will operate in any position, which facilitates piping. @ Has positive 3-way action. @ Prices are competitive. (Ant controls limited WESTERN WAY BURY ST. EDMUNDS, ENGLANDPHOTOGRAPH BY COURTESY OF “THE MARINE ENGINEER AND NAVAL ARCHITECT JOURNAL, Fig. 1. Typical Amot thermostatic valve installation aboard the "Dart Europe’ fitted in the jacket cooling water system of @ remotely controlled bow thruster Giese! engine of 1400 BHP. The arrow shows the position of the model 48-170" F we a t PRESSURE DROP. POUNDS PEX SQUARE INCH ous wo ms ) no | 0 wt 880 te Ot wD] LD ee ss. Sto 20 00RD 260 FLOW IN U.S. GALLONS PER MINUTE Recommended pressure drup is 2 te 7 ps Fig. 2 Amat thermostats Pressure drop throv GENERAL INFORMATION ON AMOT THERMOSTATS [AV AMOTthermostts ate equipped with postive .way valve ction in whch the wero lbrcating oi is postve'y made to low inthe direction require, On jacket woter pplication: when the engine i stared up ond col, the AMOT termostt causes all ofthe woter tobe postvlyby-possed back into the engine, thus providing the quickest worm-up pid posible. Alter worm up, the corre! tamovnt of water i by-passed ond outmoticly mixed wih he cold woter return ing from the heot exchanger ot ater colng device o produce the dese jcket rote outlet temperfure. If ever required, the AMOT thermostat will shut off play on the by-pass ine. The 3ewoy orton of the AMO thermast!cllows Constant volume of woter through the pump ond engine ot ol times with no pump restriction when the engine is cold Wo odjustments or service ore eve requied on ANT thexmastts. Once insoved ‘on AMOT thermostat con be forgotten about. Iti entirely sll-contoined, ond there tre no external bubs or lines fo become damaged or broken, There are mo packing ‘lands to tighten ond ne prs Yoo The temperate i permanent st ct the foctory ond requires no further edjustment. The operating temperature con be changed only by changing elements. Elements ore eaily replace by unboting the touting. Elements ore oll interchongeoble between the 2 to 6° sizes ond sies larger tho 2° contain motile elements in ene housing, This meons thot the some size AMOT element will fit eny size AMOT thermostat housing from the 2 pipe size tothe 6 pipe size model ecouse AMOT thetmostots ore set to 0 predetermined temperature ot the fctny, Cesly eros dv fo mistakes of eperatng personnel ore elimioted. Aer on AMOT thermostot has been installed, i i imposible for the operator Yo chonge the operating temperatre and ron the engine to cold unes the elements themselves are changed. The temperature conge of any AMOT thermastat ordered should fllow the engine builder's reommendotion. This information i vvely avaible from ANOT eng: meets who work dasely with he engine monufocures. A few general recor 40: tions can be mode, however. Fr diet sltwoler cooled marie engines th. model should be vied os this Yemperatre is well below the point ot which salt ‘ill deport inthe woter posseges of loge diesel engine. though i is sofe to ie somewhat higher thon this temperature its general procic to use he 120°F. Trodel for desl: ond the 140°F. model for smile gosoline marin engines with ‘Get st water coling Secalsolt water thermostats are availble of ext cst inthe 120°F, ond 140°F. model, For marine ond stetonary engines vsing best texchongers, roars, or some ofher Type of tesh woter sytem @ focket water tute temperature of 160°F is foil univers In regard 1 sie, the sie there: Stotcortesponding tothe water eutetpip sie on the engine suey sovistxtory. However, if woe How information i valle, the graph on figure 2 am be vied proximately T pounds to select he prope sie Pressure dpi svally finite per sqote iach ‘hermastothovsngs inthe 2° longed ste ond larger ore furihed in ether co iton, doce to, or all brone, The cst ton medels are recommended for es onliation becouse oftheir equal performance ato lower pre. /1" 10 1Y4", ore rade, ovget then 6° ANOT theists are abe ovible ond ore devsibed ir ther bulls, Gimensins ond weighs of AMDT thermostats ace show cn the os page ofthis bulletinAMOT MODEL“B” FLANGED THERMOSTATIC VALVES eels oan are nee (ero ame 2 2 Zz 2 : 3 i d ; ; 3 i 2BF + + 2AB + z TABLES j z TE + z 3B z $ i $ 4B 4 ars =e ee Set ae 5B = 247 o ASA Rae epEE=t oe ties Se a ae 6B age [= asa te 932 fas = Sete PRE net rs = Spe Peers ‘Amot thermontae re rated according to the expected operating temperature in Jackat water smrvice. Tha following temperature uattings sroavalapie: 249C (780F), 378C (90°F), 4196 [1059F}, 4B0C (1209F), 880 (1300F), BOOT (140°F), B62C (1802F], 68°C 55°F), 1772 11809, 7420 (1859F', 770 (1769F), 82°C (1869F), and B10C (I9EOF). Sore other ternperatire wttlnge are bv Speci! order. Salt water elements ar avllabe from stock with 49°C (1200F) and 600C (1400F) tamparature sarlngs Theres Interchangeable between all moda TO ORDER: Specity Modal No,, Temperature Setting, Hous For lubricating ol order aitng ag AMOT CONTROLS LIMITED ‘AMOT” Coairot Harels, Switcher. Thersostars and Safety Control Kaulpment Pers ELTON WORKS. WESTERN WAY - BURY ST, EDMUNDS - ENGLAND, ISSUE Et nd Flange SpitPIPING DIAGRAMS FOR AMOT THERMOSTATS ‘the two most commonly used piping dingtms for jocket water contol ore shown ' The AMOT therrcstat wil operate in ony postion end mounting in figures 0 sould be made in acordonce with conve For lbvicting oil teperotre conrl, the AMOT thermasta is wsed dtety in the lbrictng ol fine os shown in figure 6. Theol wll byposs the he techanget when cold ond will reach the desired operating temperate rapidly. ‘When worm, he coset omount of il wil be ciculted though the heat exchonger to mointain the desied termperatere automatically. The system shown in fig. 64 sfondard jacket water temperature contol sytem. In fig. 6B the AMDT thexmastt is used as @ mixing valve. Hot ol enters “B° and cad il enters "Cond the il is mixed end proportioned s0 0s 1 emerge from "A" ofthe desired temperate This system is sometimes used in connection with jock water tem- peoture contol when is desired to rciatain ocetain temperature of the wotet toverng the engine. FEATURES OF AMOT THERMOSTAT ELEMENTS is similar Fig. 3. ‘The power creoting medivm uilizes the expansion of a special thermestatic mate- til which remains in srs form ond which is highly sanive ro Yemparature ‘chong. The operating range it determined by the chemical composition of the mat Expansion ofthe moterol created by arse in tempertore develops peste thot is tansitted drt tthe piston producing a very large force which eniy over- comes the etn sping force of over 100 pounds. Construction i simple ond ugg, Yet the oni is very sensitive Yo chonges in emperatre. The elemeat con stond txireme temperstres without demoge ot change in calibration. Changes in pres- sure do nat fect the element end due Yo the volve constuction surges in pressure do not tend to upel the sobiliy of he thermastt An igre 9 shows the element with the operating piston inthe col position The wotertevels out the by-pass as shown bythe orto. 1 in figote 3 shows the pisln moved up tothe extended or worm positon The by-pass cloves off os the sliding vole sets ond the woter Moves out the tutto shown by the ert. In aclualapeotion, the sing wave is normally in aboot the mid poston, When the wnt opeetes, the exponson ofthe thermestot rateviol force a moulded synthetic rubber plo into 0 reduced diometer in the Pislon guide, which multiplies the movement ofthe piston by on extruding ection. The plug ond diphragm are of « synthetic composting. Fig. 4. Fig. 5. a0 c eae iar | Sls. en am conomowna TSH = 1 Fig. 7. Fig. 8. ys : Ie APrUcAnONS ae eea. PARTS LIST INSTRUCTION - CATALOGUE SECTION 2 THERMOSTATIC VALVES Your Anot Thermostatic Valve has been manufactured etectanle defects at the thee 4¢ left the the valve is correctly applied and” instal Hive years of ion far nestly 411 normal operating consicions, ‘Clemencs must be used. Anot has an element exchange jrogtam for sev or only slighely sted eleaenta-see Form NSPECTING THE VALVE OM ITS RECEIPT ty and thee there are 4 fee aor Tne Lorger, masber weece the velve is a 257 type, with Troe housing, —100¢F nomiaal tatingzand” che -Ol Uoilcacen standard 1096x ty Simidarty, 2 Tyaet70 (ov Snobs 28-08 Tele he lo ai tterest temperatures to a AMOT CONTROLS LIMITED LTON WORKS, WESTERN WAY, BURY ST. EDMUNDS, ENGLAND. ret After Laltielly placing the valve to ope Closely watene Jiaynten in vaicn che valves have been properly select tater the anticipated Clove ard heat rejection eaten Should operate very close £0 the valve oat fave rating. Sater coolteg #7 seo Talighiay below the somtaat teaperacace ‘oll or other viscous flvida with loves spect tt ev slighely above tbe {rom the nominal valve rating, a8 effor’ should the nouinal 1a the aaximum attoxe polae of the element Stoten valve, ‘and Beyond that) polae the valve 12 Gttectiog sll of che Moving. fluid to the © Pore ve sungene Prepatd co Aaot for checking tn our eclibrated teat Tanke. “Mose! Whenever” ahisping elements, Be sure to tap then edtvidually for protection ageinst nicks and Hleseate be shipped fon the side steno. the oely muaber fet Production control uabers.) AE LO"F above the Form 122 REV. 4 5.4Page? place the eleent int bucket of vater IDE bets for 5 auquten (lar altding valve Shad not be off Ics seat). Meat, place the ete seh cee ESP shove ule mained ex 20K ao TENE Ugsesoety toe $ atmatess Tae elewene shouts SEOUL teloned, the sa devernines by tawett Tehay placlon ow elomeat. back inthe valve Mea TRMMng ene element epider folly Tato cea Sere ne rteavel spring can be felt, the elenene TET state Pertorm the tase step wotcely Metre tne eteseat nas cooted, and D0'NOF USE ott we lua "test BATH. Gn very moph tenperatore stback will of cour SNStace (onteh are ceplacerble), Mater sdatchv Ghise suelltng of the Oveing eel arcund the al dion Sblve.eo the point whece they say affect element action Wnt require eeplacenest. Synthetic ha I eanteety attack the O-ring = Sei ceplaced by rings of alternate matertal 3eo'3 ye Of grease on the Ovriog tx helpful in te-asseably The cedptets wate model number and the correct 961 aot does not recommend hac parte be eatotalnes at the valve” inatel lation Coumonly sed elements and SONRD, from Anote’ stocking ates representative Steines Unless detinice. trouble 1s encountered Mtnen nrderion teplacesent parts for Aaot ‘Tivaye give the item nuabee, name of he parc, feevete ore rated for a shelf 1 Bie ot Setne gest fon fpaene, If alequately tested from air, they ae etl oeelter longer periods. sheif Life of the Avot TTloenta ie fom one to two yeu CcoumouLy USED REPLACEMENT PARTS aaste No. oF paste © RING douse moet dimwts MLbeavT | ELDAENT CASKET toe foes PAT Seal Paw rarer) 1 are ae Uiatcurcent 1 tate temp) 1d dot T0S3 Far (Gider) | T096e- ews) 1B 1100 Kaas aertcersene) | 1otx-CTemp.) TINY Tt 28 > Wogercttemp.) HAD Towmac(teme.) 8) Toi oe i Nogoncttene) nny 2 oe 3 towencktemes) tes "Depending oe etorane yore Tea ear ADDITIONAL ITEKS UAT HAY BE CHECKED AL 100 wus. lone mained Coaperatace selected. Bicnccelite type thermeseeere will tedicate tow Themmortatic valve greatly oversized of cooling, Tnpactty of ayetem auch greater (hon cequired. Teter tu cooler at lev craperatures. teal (sce Fore 542) Toolgrest a pevemure difference (in excess of Ts pai) between valve porte ssysni roar eRaTUNE 100 wor Coolion et Ihermvatotic valve. too saall {oF flow 6te Uso esuues igh pre cavteation) Qulve tnecalted backearda--a4 temp. Gncrease Ayoaee Vill oot close dur to vorn or pitted EUllde tutldup an elenene sliding valve prevent peesuure tn cooler) fp norteontal uve hen yorsible: ‘They thould be an tar se pos Trax the confluence of too aereans of #4t ferent OF the eleweni sliding valve (see section om vane) Gang email’ stogetype gashecs on fat (ace cast from flanges and pulling bolee too tbpst, tackPag (Amst controls PARTS LIST MODELS DESCRIPTION HOUSING ASSY. 2B 2BF WHEN COMMUNI CATING WITH AMOT REGARDING OPERATION OF A CONTROL ALWAYS GIVE THE MODEL No. AND SERIAL Now 1F ORDERING PARTS, ALSO INCLUDE THE DESCRIPTION, PART AND QUANT! TY DESIRED. 2 | UPPER HSG. f 3 | sear. 1 1092 eel hy 7% _| SLEEVE 1 1182 ca By 3 [0 RING SEAL T 1183 7_| ELEMENT _ASSY. 1 1096x * | muar Gasker 1 #6 CAPSCREW 4 LOCKWASHER wor PARTS LIST MODELS 2}B 38 4B 5B 6B ner no. UANTITY pescatption [2-1/28] 38] 48! 58 7_[woustae assy.[ 1 [a Ta Th PER ST 7 TELENENT ASST i rT iv ASHER * ORDER ELEMENTS BY BASIC MODEL Now TEMPERATURE. FG 1096%+180 + * ORDER BY REFERENCE No. , DESCRI PTION AND VALVE MODEL Now E.G. #10, CAPSCREW FOR AB VALVE, #8. FLAT CASKET FOR 38 VALVE ano. *** onoeR HOUSINGS BY STATING THE MODEL Nec AND MATERIAL REGU! RED. PER unt PART 8 | nunners| 1 | awe Se apSEZ25 FoRM 122PRESSURE DROP THROUGH AMOT MODELS "A" AND "B" THERMOSTATS WATER AND OIL (METRIC) — B- 0.7 a — 0.6 —— a SAB 40 AT 60°C» SAE 40 AT 71°C- SAE 40 AT 82°C- gO % SAE 30 AT SAE 30 AT 8 SAE 30 AT go & Zo —— 8 7 Eo. = ° i a & 138 Gémm) 2B & 2BF (50mm) 238, 33(65 & 80mm) -43_..__ (100mm) 5B (130mm) 6B (155mm) 6-20-62 150 250 500 1000 1500 2250 180 210 300 350 600 700 1200__ 1400 1800 2100 2700 3150 FLOW IN LITERS PER MINUTE 240 400 800 1600 2400 3600 270 450 900 1800 2700 4050 300 500 1000 200¢ 300¢ 4500 FORM 563THREE-WAY VALVE F84/49 1 [easae] namy Tooes | wencen | ommostdene| ence | uscveinia] ptvaiinn + Ge’ |Prakasce frwt0 |i000 tea] 2600 keg] sicce- | Flanges ar | Rektane ones 10 kp/eet| 16 kp/ed| way Ds S62 gulac tie with + bs 809 Tagulae, Pipoce socing as (oe) a bey | a Type 1-DR 68116 DN 50 Actuator type FF 83-44 type 1-DR 68116 DN 65 Actuator type FF 100-52 Type 1-DR 66116 DN 60 Actuator type FF 110-62 Teanallow Pattern ¢ 1/4 eoce. 61/4 roct. Ale Beeathee ———~-! spring close roct 2 Air” cloce Port 3 % .t 3 3 on iz 2 1. Cooling Hater Inlet 2. Charge Air Cooler bypass rN 3. To Charge Air Cooler 3. L _ Bronce | Cast Iron L DN 50 Pact.No. 700187] 023804 DN 65 Pact.No. 700188| 023809 DN 60 Part.No. 023836| 023873 i Solenoid val s eye yolr{[<«Jxjilolalvyy avo, uw S BY Yoon | 65 a0 Pars 00300 so 65] a] ae a 65005 | as [495 25 [190] 120] 360 [6s [10s | 200 | 126 » eo] 0 Tse [es | 9 [20s P30 [400 | 00 | 200 | 00 [7 86.10.05 Ler.ABB BBC ABGAS - TURBOLADER BBC EXHAUST - GAS TURBOCHARGER BBC TURBOCOMPRESSEUR DE SURALIMENTATION VTR 214 / 214A -11/-21 L141 / 7011 Vorschritt fiir Betrieb und Unterhalt Instructions for operation and maintenance Instruction de service et d'entretien crit Walslagor-Eigenscnmiorung smit Hohiwaionpumpe mit Schalldampter oer mit Luttsaugstutzen with coling-contact boasings, self lubricated with contnfugal oil pump ‘wth slancor oF wth ale suction branch ‘avec paliors& roulerents, lubrication autonome ABB Turbo Systems AG, CH - 5401 Baden / Schweiz ABB Turbo Systems Ltd, CH - 5401 Baden / Switzerland ABB Turbo Systems SA, CH - 5401 Baden / Suisse HzmL save0c ZTL1242Diese Betrebsvorscnrit bestent aus folgen- cen Blatter ldnummer Number of igure Numéro e lafigure 214000001 214020003 21402.1-001 214.03.1-001 214.03.2001 21408,1-001 214.08.2.001 21405.0.00: 234.05.0.002 214.05.0:003 214005.0008 214.05.1.001 2ra08 1-002 21805.1-003 214.08.1.008 214-08.0.002 214:06.1-002 2reorcon 214.080.0083 214-08.1-003 214-08.5.001 214-09.0002 214-09.1-001 214-093-001 214.095.001 214.09,7-001 VTR 214/214A-11/-21 L141/T011/KA02/DA01 ‘This book of instruction for use and main tenance consists ofthe folowing shoots: ‘Textblitter / Text sheets / Feuilles de texte HzTL 93780 HZTL 93781 HZTL 9«g82 HzTL 91088 HZTL 91073 | Hzrc sr3535 HzTL 91120 Anbang, Gegenstanc Seite (eenematisen) tor Komoiett igen ces Verdichters Lagereinbau Verdichtorsete agereinay Turbinenseite Lagerraumceckel Verdichterseie Lagerraumdecke! Turbinenseite Gaseintritsgenause/Dusenring/ Apdeckrins BAI {1 Ete racial A2h (2 Einttte vadhat) are (2 Eintate axa), RASTIAAST (2 baw Eintite ‘aa Anorcinung der Wasseransohilsse ‘Ur Gasentanegenause Baz Elntnt racial apt (2 Eine ‘acta Bare (2 Ernie axial), AABUAAGY (3 baw 4 Eintite radial) Gasaustiinsgenause/Fusse Anotcinung cor Wasseranschlisse fdr Gasaustitegonauto steintrt-/Lutaustettegenause/ ineatzwanaiOvfusor ‘Schalidimptor KAO Iter reinigen und Fitertullung Luftsaugstutzen ‘us: und Einbau der Lager und ‘os Fotos [Abschlussvotrichtung Blockieron dos Rotors Konserieren des Turbolacers Spiel Uste der Vertetungen und Sencestalen HEIL 1047 MEL 93782 HZTL 1048 HZTL 94983 HzTL 91133 HZTL 9107S HzTL 91074 HZTL 97967 FzTL 91052 HZTL 91121 HZTL o7oaa HZTL 97396. HZTL 97985. HZTL 97988, Appendix Designation Sectional éravang (schematic) tor complete Cleaning the comoressor Beating assembly comoressor enc Beating assembiy turbine end Beating space cover compressor ona ce 19g space cover turbine en Gas init casingiNiozze rng/Cover Bako (1 enuance radia) $021 2 errances rasta ‘72 B entrances axa) AABIIAANT (Sen. 4 anrances racial Disposition of water connections for gas inet easing A121 entrance radia) ‘A2I (2 entrances racial) ‘are (2 entrances axial) AAGI/AAST (Gresp. 4 entrances ‘adal) Gas outet casing/Feet Disposition of water connections for (938 outlet easing, Air inlet easing/Ai outlet easingy ‘WallinservOiRuser Silencer KAa2 Cleaning the fiter and replacing the titer mesh Ne suction branch emoving and inserting the bearings ana the ros Blanking device Locking the rotor Metnbaling the turbocharger Clearances LUst of agoncies and service stations Cotte instruction de sence et dlontreten comprend les fouls suvantes: HzTL 97968 HZTL 94986 HZTL 94985 HzrL 91138 HZTL 93783 Annexe Designation Coupe yschémanique) Potor complet Nottoyage du compressor Corps de palier co%6 compresseur Corps de palier co%6 turbine Couvercle do chambre do pal compressour Couvercie de chambre ae palier cbxé turbine at dente des gaz/Distibuteu/Anneau derecouvrement ‘AID (1 entree raciale) $821 (2 enuiees radiaes) ‘APD (2 entibes axiales) ARSIIAAST [Bresp. 4 entrées racials) er) Disposition des raccords a'eau pour bat Gente dee gaz SA12 (1 entrée radiate) A21 (2 enttees raciaies) are [2 entiges axles) RASY/AAST (3 resp. 4 entides raciales) ‘Bt de sortie des gaz/Pieds Disposition des raccorae d'eau pour Dat Ge sorta ces gaz Bati dontrée c'an/Volute de sone oi Recouvrement fixe de la rove Oituseur Sllencieux KAc2 Nettoyage du titre ‘itrante fomplacer fa masse Tubulure aspiration ale Extraction st mise en place des palers eteu rotor Dispositit debturaion Blocage du rotor Conservation du turbocomprossaur Jeux Liste des représontations ot des stations de service ABB Abgas-Turbolader VIR mize HZTL 937816 |nhaltsverzeichnis Contents Table des matiéres 4 Technische Daten 0.1 Technical cate 0.1 Caractéristiques techniques )2 — Ersatzteiibestellungen oder 0.2 Ordering spare parts or requesting -«9.2-«=« Commander des piéces ce rechange ilektragen informations ‘ou demander des renseignements 13 Unerwacrungsprogramm 0.3. Check lst 03 Programme des contiBles )4 Allgemeine Bemerkung 04 — General note 04 — Remerque générale 4.1 Inhatt 0.4.1 Contents 061 Matiére 342 Bilder-Numerierung 0.42 Numbering of figures 0.42 Numérotage des figures DS Autbau des Turboladers 05 Description of the turbocharger 05 Construction du turbocompresseur D7 Lagerung von neuen Turboladern 07 Storing new turoochargers 07 — Mise en dépét des turbo- ‘compresseurs nouvesux L_ Betrieb 1 Operation 1 Service 1.0 Schmierot 1.9 Lubricating oll 10 Huile de lubrifcation 1 E’stes inbetriebsetzen 1.4. Commissioning 1.4 Premigre mise en marche 11.0 Vor dem ersten inbetieosetzen, 1.1.0 Before taking into service 1.4.0 Avant la premire mise en marche 1.1.1 Beim ersten inbetriebsetzen 1.1.1 When frst taking into service 1.1.3. Pendant la premiére mise en marche 1.42 Nach aen ersten 100 Betrions- 1.1.2 After the fist 100 hours in service 1.1.2 Apres les premibves 100 heures de stunden marche 1:3 _Uperwachung und Unternalt 1.3. Checks and maintenance 1.3 Surveillance et d’entretien 1.5 Inbetviensetzen des kenservierten 1.5 Taking the mothballed turbocharger 1.5 Mise en service du turbo- ‘Turboladers into service ‘compresseur conservé 2 Unterhalt 2 Maintenance 2 Entretien 20 Peinigungsarbeiten 20 Cieaning 20 Nettoyage 200 Luititer 200 Aictiter 20.0 Fire d'aie 202 Kihiwassertaume 20.2 Cooling water spaces 202 Chambres d'eau de retroidissement 203° Olréume 203 Oil spaces 20.3 Chambres a huile 204 Tutbinenseite 204 Turbine enc 204 Coté turbine 205 Verdichterseite 20.5 Compressa: end 205 Cote compresseur 208 Reinigen des Verdicnters im Betried 2.0.8 Cleaning the compressor in service 2.0.6 Nettoyage du compresseur en serwice 21 Zerlagen und Zusammenbau ces 21 Dismantiing anc assembling t 21 Démontage et montage cu ‘Turboladers turbocharger turbocompresseur 21.0 Aus-und Einbau cer Lagereinbauten 2.1.0 Removing and replacing the bearing 2.1.0 Extraction et mise en place des assemblies corps de plier 21.1 Aus-und Einbau des Rotors 2.11 Removing and replacing the rotor ——2.1.1._Extraction et mise en piace du rotor 21,2 Zetlegen und Zusammonbau des 2.1.2 Dismantiing ana assembling the 21.2 Démontage et montage du rotor Rotors rotor 2.1.8 Ausbau und Einbau des Abdeckringes 2.1.8 Removing and replacing the cover 2.1.3 Démontage et montage de sing sAneaU Go recouvrement 2.14 Aus-und Einbau des Disenringos 2.1.4 Removing and replacing the nozzle 2.1.4 Démontage et montage du sing distributour 22 Ersetzen einzeiner Toile 22 Replacing individual pans 22 Ramplacer des pidces individuelles 220° Disenring 220° Nozzle ring 220. Distibuteur 221 Dichtungsbiichsen 22.1 Sealing bushes 2.2.1 Douilles d’étanchéits 223° Turbinenschauteln 223 Turbine blades 223° Ailettes de turbine 224 Prailplatten 22.4 Battle plates 224 Détlecteurs 225 Walzlager 22.5 Roliing-contact bearings 225 Paliers & roulements 26 Spi 28 Clearences 26 Jeux 27 Lager 27 Bearings 27 Paliers 2.8 Konservieren des Turboladers 28 Mothballing the turbocharger 2.8 Conserver le turbocompresseur 29 Normal-Reserveteiie 29 Normal spare oarts 29 Pidces de reserve normaies 29.0 Verzeichnis der Normal-Reserveteile 2.9.0. List of normal spare parts 2.9.0 Liste des pidces de réserve ‘normales 3 Stdrungen 3 Faults 3 Anomalies de fonctionnement 20 St¥rungen und mégliche Ursachen 3.0_—_—Faults and possible causes 3.0 Anomalies et causes possibles 3.1 Stilsetzen des Turbola: 341 Taking the turbocharger out of Sut Mise hors service du turbo- service ‘compresseur 8.1.0 Beheben eines Scha 911.0 Rectfying defects with available 2.1.0 Remise en état avec des pidces de ‘vertugbaren Ersatzteilen spare parts rechange disponibles S14 Ausbauen des Rotors und Anbringen 3.1.1. Ramoving the rotor and fitting the 3.1.1 Démontage du rotor et montage der Abschlussvorrichtung blanking device du dispositi ¢’obturation 9.12 Einbau der Blockiervorrichtung 3.1.2 _Fiting the locking device 31.2 Montage du dispositf de blocage 9.1.2.1 Blockieren auf Turbinenseite 3.1.2.1 Locking at turbine end, 3.1.2.1 Blocage coté turbine 4 Teilnummern-Verzeichnis 4 Index of part numbers 4 Nomenclature 40 Turbolader 40 Turbocharger 4.9 Turbocompresseur 44 Warkzeuge: 41 Tools 44° Outils 44 Abschlussvorrichtung 44 Blanking device 44 Disposit ‘obturation 45 Blockiervorrichtung 45 Locking device 45 Cispositif de blocage 4.6 Konservierung 46 Mothballing 4.8 Conservation ABB Abgas-Turbolader VIR..4 HZTL 9498280.1 Technische Daten Technical data Caractéristiques techniques Dieselmotor Diesel engine Moteur diesel Hora Manutacturr Constructour avant und Typ Design and type Type Nennieiatung in ates output in Puissance nominale en Nennarenzani in Nominal speed in BERGEN DIESEL KRG 6 Ps) 1023 kw (hp) - (en) 3 (min") Y¥esse de rotation nominale en Aufstalungshohe UM. in Aituce above soa-ieve in Aiitudo au-dessus cu niveau de la mer on Ansaugluttemperatur in intake ai temperature in Keo) Température ce Fair aspiré en CChne besondere Angabe geiten folgence atmosphiische Bedingungen: Amospharen - Oruck Ansaugluttemperatur t= 0.02 bar = 100+- 2kNim? M0+-6K = 274-6 Unions stated otherwise, the following atmospheric conditions are assumed: Arpressure Air intake temperature Sans incieations special Pression atmosphérique Temperature ce ric asp ‘Angaben auf dem rating plate Specifications au plaque signalétique Fichtwart fir die Betriebeda Approximatve value Valeur aporoximative Fichtwor tir dle Betiebsdk Aoproximative value for Valeur appreximative do {+= 0.02 bar = 100+- 2kNim? 300+-6K = 27+-8°C los conditions atmosphériques suivantes servent ce base: 1++:0.02 bar = 100+= 2kNim? foeee 2 fhee pence BBC Shantdtteccnaoe ‘Enbcteeresser ae Seienton Typ VTR 214-11 Ree 038 *f. No. HT *) tase 680 °C Specification v 01113 R 012 H 04109 Ww 12206 E 03218 U 023 L 241 T O11 12/ er Walzlager (she § 2.25): 3 ring contact bearings (#8 § 2.25): durée de service des paliers & roulements (voir § 225): dos Vorsichterades: 18 life of compressor whee ‘ur6o de service de Ia rove de compresseur *)388895 388096 3963.22 RF 3.90527 ‘Abgas-Turbolader VIR..4 HZTL 910441F0.2 Ersatzteilbestellungen oder Ruckfragen Bei jeder Ersatz oder stelung icktrage ist anzugeben: Typ VIR ‘Gomase tacnnisenen Daton § 0.1 oder Newt Leistungssenild am (Fabikat.) He Turbolader Ne Gomass Bide im und ‘Annang und Teil-Ne. Bezeichaung We Verzeichnis § 4 Stickzah.. Bite auen dio Nummer ces Bildes - am ‘oberan recnten ldrand des Blattes - an- geben, siene § 0.4.2. Unsere Verretungen und Servicestelen ~ siehe Servicestelen-Lisie em Ende dieser Betieosvorssnnit- sahmen_Bestellungen ‘Gr Ersatttale enigegen. Sie erteien auch Auskuntt, falls in der vorlegenden allgemeinen orschait vesonaere Falle ‘ient berucksicntigt sein solten Beispiele von Ersatzteil-Bestellun- gen oder Rickfragen Turbolader VIR. Fabiikat-Nummor HT 1 Rotor kop. Teil. 20000 Bild VIR..4-020...*) bei Serie -11/-21: 1 Gaseinuitsgenause mont, mit Kernioct- ‘oeckel, eile. 50000 Bild VIA 4.05.0... *) (Stutzenstelung ces Gaseintitsgeniuses angeben) *), 1 Sate Kesnlochceckel um Gacointits- gehéuse, Ter. 52000 Big VIR.4-05.1-..*) (Stutzenstellung des Gaseintitegenauses angeben) *) bei Serie -32/-12: 1 Gaseintaittegenause mont, TeilNr. 51000 Bad VTR805.0-.°) *) Nummae der Bilder im Anhang, siahe 9 042 +) Ole Stellung der Gehiiuse und dor Fusse wid von Turbinensaite gosehen 0.2 Ordering spare parts or requesting informations Cxders for spare parts oF correspondance should quote the following: Typ@ VIR wll 98 par technical data § 0.1 or NowT ‘ating plate on (SeriaNo)” BE turbocharger Part num! 28 per figures and ang parts list cesignation I 64 Quantity Please also quote the gure number at the top of the sheet, see § 0.4.2. (Our agencies and service stations - see lst fof the service stations at the end of this ‘manual - will accept orders for spare parts. They will so give advice should a special ase arise wrich is not covered by these in- Examples of spare part orders or information requests: Turbocharger VIR... Svial number HT 1 rotor compl, part no. 20000, Figure VIR.8'020. For series -11/-21: 1 Gas inet casing ass. with cove hole covers, part no. 50000) Figure VIR .4050-..*) (dicate branch position of the gas inlet ceasing) *). 1 Set of core holo covers for gas inlet ‘casing, part no. $2000 Figuee VIR 405: For series -32/-42: 1 Gas inlet casing ass., part no. $1000 Figure VIR 605.0 *) The umber ofthe figures are speci- fied in the appendix, so § 0.42 **) The postion of the js elwaya stated relative tothe tur 0.2 Commander des piéces de rechange ou demander des renseignements Chaque commande es piéces de re change ou craaue camands de renee ‘rant det menvonner Type VIR selon caractéristiques techniques § 0.1 ou NowT plague signalétique du (No. ce fabs.) I turbocompresseur salon figures No. ot bnomination do la pibce Quant Inciquer te numéro de la figure, en haut do a page, voir $0.62. ‘Nos représants et font iournit les ideas ot fechange ‘et donner tous ‘ments concernant les probiémes 6ventuels hon tats dans corte brochure d'un ccaractére général, Exemples des commandes des pigees de rechange ou des demandes de renseignements: Tubocempressour VIR No do fabsieation MT. 1 rotor compl, pidee no, 20000 Figure VIR 4.020...) Pour les séries - L1/-21: 1 BB centiée des gaz ass. avec couvaicies do noyaux co fondene, pidce ro. $0000 Figure VIR 4.05.0... *) Vorlantation du pati entiée des 1. Jou de couvercies de noyaux ce fondevie pour Dati deniibe des gaz, pidce ro. $2000, Figure VIR .4-05.1~. *) (iadiquer roviontation du biti dentise des 9m)“, Pour les séries -32/-42: 1 BAH centiGe des gaz asa, pide ro, 51000 Figure VIR 050... *) *) Los numéros des figuras sont inclqués dans rappendice, voir § 0.4.2 an see tation ot oe dot st te ase too oa [ane gas Turoloder VERA iar oo0.3 Uberwachungsprogramm Vor dem ersten Inbetriebsetzen Siahe 61.1.0 Beim ersten Inbetriebsetzen Siohe $11.1 Taglich neg 13 Alle 28. Sighe 9 205 Nach den ersten 100 Betriebsstun- den Siohe § 1.12 Alle 1000 Betriebsstunden Vsiene 6.0 Periodisch je nach Anlage Siohe § 2.0 une § 26 0.4 Allgemeine Bemerkung bn jeder Betnebsvorschrit liegt ein golbos Abieissbiat und win adressirier Urnschiag (ABB Turbo Systems AG. Ant ZTV-S3) boi Fur Diensiastungen unserer Servicestlian ist es voreihan dass. cer Turbolader herstelor (ABB Turbo Systems AG) durch ‘don Endabrehmer uber die betrettende An ‘age informer wi 0.4.4 Vinhait Text und Tolnummemnverzeicnnis sing onereil tur verschadene -Austuhvungs: Vatianten von Turboladern abgetasst. Dom zufoige sind im. Teinummernverzeichnis ‘uch solene Bestandtaile aufgetunnt, ie beim geletertan Turbolader eventual richt vothanden sind. Missverstandnisse werden adurcn vermieden, cass ie im Arinang vothandenen Zeichnungen mit Tellnum= ern watgehend der Turbolacervariante, ‘ie #s Bestelung geletert wurde, fentsprechen 0.3 Check list Before taking into service See 1 When tirst taking into service S006 1.1 Every 25..75 hours in service swe §206 After the first 100 hours service Soo § 1.12 Every 1000 hours in service See § 1.0 Periodically, according to the plant See $20 ana's 26 0.4 General note A yellow tear off sheet and an addressed envelope (ABB Turbo Systems AG. Abt ZIV-S3) is included in each insttucton Any information the manufacturer of tha 6x: haust-gas turbocharger (ABB Turbo Sys. tems Lic) recewes from the user will be helpful fr later assistance 0.4.1 Contents The text and list of part numbers nave len prepared £0 a8 to be generally ao- plicable 19 the various designs of tur- Dochargers. Conseauertly the list of part numbers may contain parts which are not present on the machine supplied. To avoid Tisunderstanaings, rewever, the figures in the appendix, togeiner with part numbers, largely. cortesooad to the model of tur: Docharger ordored, 0.3 Programme des contréles Avant la premiére mise en marche Voir § 1.1.0 Pendant la premiére mise en marche Voie § 1.1.1 Journellement Voir 6.1.3 Toutes les 25..75 heures de marche Voir § 20.8 Aprés les premigres 100 heures de marche Voir§ 1.12 Toutes les 1000 heures de marche Voir § 1.0 Periodiquement, selon installation Vor 201625 0.4 Remarque générale Ghagus exter Sternicio Jo erica content une feuile June f atachor tna Gilune envsoonegonam taatese, (8 Tnbo Systome AG, Bot TVS) Pour les interventions ventuelles demos Stations ¢e service il est avantageux que fabneant cu turbocompresseur (ABB Turbo Systems $A) regoive une informa tion de instalation en question, 0.4.1 Matiére Lo toxte et la nomenclature ce Dreserietion de service sanpliquent & di forentes vananes G'éxecution ce tur. ocompresseur cu suralmentation. il est ‘cone fait mention également de certaines pidces qui ne se retrouvent pas sur la Iachine lua cans le cas pariculer. Par contre les dessins et coupes avec leurs numéros de position dans Vannexe cor Fesponcent assez exactoment & la variants du matériel fourn co qui dvite tout malan: tend ABB Abgas-Turbolader VIR.4 HZTL 9073/1 |0.4.2 0.4.2 Bilder-Numerierung Die Nummer der Bilder im Anrang Numbering of figures The numeer of figures nthe appenaix VTR ©" 4-05.0-""14 Im Text werden die Bilder ces Annanges ur miter Einercnungs-Nummer an: egeven In the text, the classification number only stands forthe figures of the appendix 0.4.2 Numerotage des tigures Le numero aes figures ae Vannexe son Aenderungscode Code for modification Code pour les modifications Laufnummer Consecutive number Numéro courante Einordnungsnummer Classification number Numéro de classification Ladertyp und Grisse ‘Type and size of turbocharger ‘Type et grandeur du turbocompresseur Dans Je texte, las figuies ne sont inscites ‘quavee laur numéro de ciassiicaton r [x0 igus Trader VTRA HZTL 910732C |VTR 214+354-11/2105 Autbau des Turboladers Der Turbolader bestent Im wesentichen fs einer Turbine und einem Verdicnt! die zu emer Einheit susammengebaut sind Ole Abgase des Dieselmotors durch sxémen das Gaseintritsgenause 51000, ‘entepannen sion im Dusenting 56001, ‘geben an den Schauteln 25000 Leistung 8b und gelangen dureh cas Gasaustit- fsgenauso 51000 und Guten eine ADgas- leitung ins F Ole fur den Sotleb ses Cisseimotors ctige Luft gelangt durch einen Saugstut yen. 62000" oder einen Schalladmoter {81000 in das Vorschaltrad 26000 und cas Verdichterrac 25000, durchstiémt den Dit- fusor 79000 und veridsst den Lader durch don Orucketutzen am Luftausattegehause 74000, Eine Zwisehenwand 23000. mit Wirme: ‘Solationsawiechenraum went den Lut ‘aum vom Gasraum Durch don Kanal X wird Sperrutt vor Ver ichtor zur Labyrinthaichtung des. Tur Dinontotors geletat. Sia vernindert, ass Abgase in den Ausgieichkanal Z und cen Lagerraum stromen konnen, Der Rotor lautt in den an beiden Encen blasisch adgestutzten, leicht zuganglicnen Walalagern Jeder Lagerstelle ist eine Schmier. und ikunlvorrientung 2ugeordinet De Lagerraumdeckel sind im allgemeinen mit je einer OleintUle, einer Clabiass- Otfrung und einem Cistandsalas versenen. Die Kanale ¥ (@ilé 07.9) und Z dienen 2um Druckausgieicn er Lagarraume und ver- hindern Clveruste. 07 Lagerung von neuen Tur- boladern Neve, 2 Werk galisferte Turblader konnen 12 Menate ab Leferdatum chno speziele Konservierungsmassnshmen an Wwockenen rien von” durenschnitticher Luftleuemtigkeit gelagen wercen. Vorgenen fir die erste Inbetriebsetzung eines neuen Turbolasers, siahe § 1.1 05 Description of the turbo- charger The turbocharger consists essentily of a LUice and'a sompressor,sesembied #5 & single unt ‘The exhaust gas from the alesel engine flows through the gas inlet casing 51000, expands in the nozaie rng 56007, impars ‘energy 10 the turbine lads 23000. and passes via the gas outet casing 61000 and an exhaust pipe into the atmosphere, ‘The air required for the diesel engine pas- ses through a suction branch 82000 oF a si- Tencer 81000 to the inducer 26000 and compressor wheel "26000, flows througn ‘he difuser 79000 and finally leaves the turbocharger via the pressure pipe of the air outet casing 74000. ‘A partion wall 23000 with heat insulating Inworepace separates tne air chamber trom the gas chamber. ‘Sealing air for the labyrinth glands of the turbine rotor is obtained trom the blower ‘through passage X This prevents exnaust (gas from entering the balance chamber Z Sr me Dearing housing. The rotor tuns in spring-meunted «oling contact bearings. They are readily acces- sible at Noth ends of the rotor. For each bearing thor ‘il cooling system. is a lubricating ana The covers of both bearing chambers aro generally fitted with an oil niet anc outlet Spening and a gauge-glass Passages Y (fig. 07.0} and Z allow the pros. sures inthe bearing spaces to oo balances and prevent loss of ol. 07 Storing new turbochargers Now turbochargers, delivered ex. works ‘can be stored for 12 montne from the sate ff dalivery in @ cry place with an average humidity and without taking special precautions against corresion, ‘See § 1.1 for initial commissioning proce dures of a new turbocharger 05 Construction du turbo- compresseur Ls turbocompresseur se compose essen: tiollemont d'une turbine et d'un comores: ‘sour assembles en un groupe moncbice. Los gaz d'echappement du moteur diesel, Ala eorie ce Ta culasso sont dings 4 Tuavers la candulte jusqu'au pati dentrbe das gaz $1000. Ils sont ensuite détendus ane lo distibuteur $6001 et paasent par Tes allates 29000 de la turbine. ls sont fenfin evacués & Vair bre dans une con- Cuite diéchappement montée sur le bat Ge sonie des gaz 1000. Laie st aspiré parla tubulure 82000 ou Io Silanciowx 81000, puis guide cane la roue 'amont 25000 et ‘comprimé dans ia rove de compresseur 25000 ot ie cifuseur "79000. II'est ensuite onvoye par Ia volute 8 sortie dir 78000, Une paroi_intermeiaivo 22000 avec ‘chambre Gisolation de chaleur separe Ie 9s gaz. Le canal X améne de Tair de barrage du compresseur vers No lebyrinine de Tarbro do turbine. Cot air empécne les gaz co passer dans ie canal Zt la chambre du paler Le rotor touine dans das paliers a roule: ‘ments montés élastiquement. Leu dispos- tion en bout c'arbre les fend asément ac cessibles, lly aun dispositt de lubrication et de jeffoidissement ce I"huile pour checun ces pliers Les cowvercies ces chambres de aller sont en géneral munis dun oifee pour le femplissage cihuile et d'un office de vidange ainsi que dun verre de niveau Les canaux Y fig, 07.0) st Z serent & ‘Squilbror los pressions des chambres do Palio ot & 6vitor dos fuites hui 07 Mise en dépét des turbo- compresseurs nouveaux Des nouveaux turbocompresseurs peuvent aire entreposés durant 12 mois a parr de Ja dato de lwraison, sans mesure spéciale {de conservation, & condition «etre placts 2 un endioit seo ou Fair présente une humidité moyenne, Pour Ia premiére mise en marche dun owveau tucbocompresseur, voit § 1.1 ABB. Abgas-Turbolader VIR.4 Ta |1 Betrieb 1.0 Schmierd! Nazlager Eigensenmierung exikation 1141 oder L283, TO11 *) ‘Negen der honen Alterungsbestandigheit sind Turbinenote 2u verwendlen, ie Viskositar muss in den folgenaen Gren legen: 1 Operation 1.0 Lubricating oil Rolie contact Bearings, soi lubricated Speciicaion: Utat er L2at, Tort *) Owing 10 the better resistance against ‘ageing, turbine oils shoula be used. ‘The viscosity must be within the following lit: 1 Service 1.0 Huile de lubrification Paliers a roulements, 8 lubrication autonome Spbcification: Uist ov L2ai, Ton *) 1 faut employer des hues de wrbine les sont resistantes au vieilissement, La viscosité doit ¢te comprise dans les limites suivante: Centistoke | Engeler Redwood No.1 Saybolt Universal bei | | | at 323K (50°C) (12°F) 30-58eST (1m AOT3E | 125-225see.R1 140.253 S.8.U | | a Das entsprcnt den folgencen Viskosi satsklasson bei at 313K (40°C) (104°F) a +) Siehe Leistungsschild aut dem kbgastur- Dolacer ocer aut Gem Blatt mit den teen. rischen Daten am Anfang dieser Eotiebs. vorschritt 0 Olmenge um Fallen beer Lagerdume wid urge {ahr ieigance Oimenge bendtgh Olwechselperioden Das 6 muss spstesten stunden gewechseit wer ‘der Nouvalisaionszanl dart maxims! 2m9 KOHIg betragen und die Zunahme der Vis- kositat hochstons 20% This contesponds cosity graces: the following vis: 1) See rating plate on the exnaust.gas tur- ocharger of on the sneet with the techn data at the beginning of tis book (60.1) Oil quantity To fil both bearing spaces the following approx. ol quantity is neccesary: Cola cortespone aux degres de viscose YGS5,77,78,82 +) Voir a plaque signalétique sur le tut ocompresseur ou sur ie foulle avec tes caractéristques techniques au début ce cette instruction Ge service @ 0.1), Quantité d'buile Pour remplir les deux chamby ifaut environ la quanti huile suivante: Interval for oil changes ‘The cil must 5 changed at least every 1000 nou's in service. The increase of tho neutralization factor must not exceed 2 fang the viscosity must not rise Périodes de vidanges d'huile hulle de graissage est & remplacer au moins toutes les 1000 houres do se lisation peut ‘maximum ot ia viscoaité ne dot p ‘enter do plus 60 20%. Abgas-Turbolader VIR.4 HZTL 91047/1K